Session 10-11 Lean Manufacturing

Atanu Ghosh
atanu.ghosh@nevaehtech.com

20-Dec-08

Agenda

Lean Manufacturing Six Sigma Adaptive Manufacturing Perfect Plant

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What is LEAN?

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What is LEAN?

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What is LEAN?

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What is LEAN?

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Lean manufacturing - roots

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What is LEAN?

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Lean Process Basics

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Lean in historical context

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10

Why are companies adapting LEAN?

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11

Typical benefits of Lean Manufacturing

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12

Principles of Lean Thinking

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13

Value stream mapping

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14

Eliminating Waste

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15

Eliminating Waste

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16

Eliminating Waste

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17

Eliminating Waste

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18

Create Flow Cellular Manufacturing

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19

Create Pull Kanban

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20

The Toyota Way 14 Principles

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21

The 4P Model and where most companies are

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22

The Toyota production system

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23

The Toyota production system

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24

Heijunka Load leveling volume and mix

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25

Heijunka Load leveling volume and mix

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26

Demand Flow Technology from JCIT International

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27

Demand Flow Technology methodology

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28

Demand driven supply chain

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29

What is Six Sigma

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30

Three sigma versus six sigma performance

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31

Six Sigma Practical implications

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32

Why Lean AND Six Sigma?

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33

Six Sigma Roles

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34

Six Sigma DMAIC Process Improvement Methodology

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35

Customer driven process philosophy

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36

Six Sigma and Traditional Quality Management

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37

Adaptive manufacturing

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38

Adaptive manufacturing

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39

How can companies run manufacturing at the speed of business?

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40

What capabilities a manufacturer needs to be adaptive?

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41

How can Lean-Sigma manufacturers become adaptive?

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42

Maximising shareholder value with adaptive manufacturing

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43

Why should Lean-Sigma manufacturers become adaptive?

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44

Flat world dynamics

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45

Need in a Flat World

Quality Flexibility to operate over a span

Speed (Process Efficiency) with minimum waste, maximum asset utilisation

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The Perfect Plant

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47

The Perfect Plant

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48

The Perfect Plant

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The key opportunities in manufacturing

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50

The customers path to a perfect plant: aligning with enterprise objectives

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51

The summary of business implications and example metrics

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52

Customer response: KPIs and best practice adaption to improve customer service time to commit

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53

Manufacturing responsiveness: KPIs and best practice adaption to reduce cost cycle times

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54

Manufacturing efficiency: KPIs and best practice adaption to reduce cost capacity utilisation

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55

Manufacturing efficiency: KPIs and best practice adaption to reduce cost COGS

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56

Manufacturing efficiency: KPIs and best practice adaption to improve quality OEE, 1st Pass Yield

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57

A Journey: Steps to perfect asset utilisation needs to be tightly coupled as a part of continuous improvement

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58

Connecting the top floor to shop floor by looking at business implications, strategic goals and value drivers

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59

Perfect plant characteristics vary by industries

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60

A Perfect Plant in a Flat World

Quality

Flexibility to operate over a span

A Perfect Plant

Speed (Process Efficiency) with minimum waste, maximum asset utilisation

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Reference books

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62

Next Session: Case Study and Quiz

Atanu Ghosh
atanu.ghosh@nevaehtech.com

20-Dec-08

63